The Industrie 4.0 plant

The 2017 Set-up

Intelligent, modular – ready for use in industry:
The Industrie 4.0 plant from SmartFactoryKL

New Developments for Hannover Messe 2017

Cross-site production

In 2017, the expanded Industrie 4.0 production plant of the SmartFactoryKL partner group appears in a new layout: for the first time, the modules are no longer set up in one line but distributed over two production cells as well as a manual work station. Products can now be manufactured in different ways – thanks to the use of the flexible transport system. Furthermore, the production modules, the general infrastructure and the IT systems are all interconnected.

2 Flexible Transport Systems (FTS)

3 Supply Infrastructure

4 Manual Workstation

5–9 IT Systems

Modular Cell 1 & 2

1a. Storage

1b. Bottom Engraving

1c. Clip Mounting

1d. Force Fitting

1e. Laser Marking

1f. Weighing

1g. Quality Control

1a. Storage

The STORAGE MODULE by Pilz is an intelligent, automated warehousing module, used to store the workpiece transporters: If the central server sends a new work order to the module, thereby, requesting an additional transporter, the storage module supplies an empty workpiece carrier from storage. Empty workpiece carriers or semi-finished products can also be returned to the warehouse.

1b. Bottom Engraving

The module Bottom Engraving by Festo initializes the digital product memory to a specific production order via RFID. The production order is loaded from a Web Server of the superordinate Enterprise Resource Planning system (ERP) via http-protocol by means of a specially developed Web Client. Corresponding to the product memory, an individual engraving is performed via a CNC engraving control.

1c. Clip Mounting

In the following production step, the CLIP MODULE by Bosch Rexroth mounts a retaining clip to the plastic bottom.

1d. Force Fitting

The FORCE FITTING module by Harting performs the central mounting of the two housing parts. The bottom with a mounted retaining clip is assembled with the cover chosen in one of the two available colors, as per customer request. The Harting module puts the lid on the base plate with a robot and embosses both parts together.

1e. Laser Marking

The module LASER MARKING by the company Phoenix Contact uses a laser system to put an individual engraving on the topside of the business card holder. The engraver displays the digital business card as QR code. Individual data can be flexibly changed upon the client’s request right up to the corresponding process step.

1f. Weighing

The WEIGHING MODULE by Mettler Toledo determines the weight of each product by means of a precision scale. The metrological quality control compares the product memory with the actual assembly status.

1g. Quality Control

The module QUALITY CONTROL by Lapp Kabel performs two tasks: Product end control by means of a high-resolution camera as well as the final output of the finished business card holder.

Flexible Transport Systems (FTS)

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2. Flexible Transport Systems – FTS

The ROBOT PLATFORM by Festo is a self-navigating robot system that links the various production cells and manual assembly stations with a flexible, material transport solution. A WiFi connection to the manufacturing execution system (MES) ensures an optimal material flow.

Supply Infrastructure

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3. The infrastructure of the Industrie 4.0 system

A powerful, flexible infrastructure is required to universally combine manufacturer-independent production modules with a minimum of configuration effort. Such an infrastructure can assume all major supply and management functions. These functions include the energy supply, data routing, and comprehensive safety controls. The infrastructure is the connecting lifeline between the production modules, which are otherwise fully autonomous. It is also modular in design and enables the connection of manufacturer-independent production modules. Standard plug connectors link manufacturer-specific infrastructure boxes that are designed as separate boxes, each with two module supply interfaces.

Manual Workstation

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4. The Manual Workstation

A MANUAL WORKSTATION is also connected to the process via the robot platform, a system created by MiniTec. Internet and communication systems provide optional support to the worker for various assembly tasks from an ergonomically perfect work station. Thanks to the Augmented Reality systems developed at SmartFactoryKL , an individual process step or even an entire production process can occur completely manually. Augmented Reality – the connection of real-time pictures with recommendations for actions – offers many advantages, especially for training processes and assembly with many variants. Through an integrated RFID reading and writing device, the employee can read out the current production progress of the product as well as the clientspecific information. Augmented Reality Technologies support him with the implementation of the variable tasks. Mobile devices like tablets, smartphones, smartwatches, and smartglasses are useful in providing an appropriate mobile support to the worker.

Integrated IT systems for the Industrie 4.0 production plant

Industrie 4.0 also stands for a close integration of automation and IT systems. The guiding principle behind all this is the synchronization of real and digital worlds for the purpose of achieving transparency and computer-assisted optimization. Information about the production modules and products is digitally recorded in real-time and sent to the modular IT system. New database-oriented services for the production environment are developed and implemented on the basis of digitally available data. The following IT systems and vendors are integrated in the manufacturer-independent Industrie 4.0 production plant of SmartFactoryKL:

5. ERP

6. IT Infrastructure

7. Engineering

8. IT Security

9. MES & Digital Twin

5. Enterprise Resource Planning System- ERP

The integrated ERP system by proALPHA controls the processes in the Industrie 4.0 demonstrator and keeps them transparent. The solution is able to create an integration between the levels of the classic automation pyramid and provides an user interface for the customer. The product configurator in conjunction with a Web Service allows intuitive and location-independent orders in the browser by the customer down to batch size one. Feedback from the plant is observable in real-time and the customer is informed about the current status of production progress.

6. IT Infrastructure

Connected Factory Architecture from Cisco aims to link IT and automation technology by connecting intelligent networks, server-architectures, and a unified communication architecture. This achieves the company requirements for a modern Industrie 4.0 environment and facilitates applications in the areas of preventive maintenance, multimedia remote-access to the units, and a remote maintenance concept. The current productivity can be derived from the digital images supplied by the Cisco Asset Manager.

7. Engineering

EPLAN Software & Service is responsible for engineering the Industrie 4.0 demonstrator. An interdisciplinary management approach to the automation of the individual production modules is critical for the design, efficiency, and operational safety of Cyber Physical Systems (CPS). The documented control system for the entire supply chain and the complete product life cycle is used as a comprehensive consistent database. The goal is to consider insights from the entire supply chain early in the design phase or the PLM process (product life cycle management). The generated documentation, for example, is suitable for a professionalized maintenance scenario or to optimize the energy balance.

Moreover, TÜV Süd has drafted a design for a modular certification method for flexible production plant structures. Specifically, these safety and legal issues have not been thoroughly addressed in the past and represent a potential showstopper. The new certification methodology includes a specific timetable, which makes the practical advantages of Industrie 4.0 achievable.

8. IT Security

CodeMeter by WIBU-SYSTEMS provides the technology required to achieve comprehensive and strong IT security standards in Industrie 4.0 production facilities. It protects software components against unauthorized access and manipulation. Cryptographic keys, e.g. used for authentication in OPC UA, are stored and used securely on CmDongles. CodeMeter’s license management capabilities allow fine-grained controls over software’s features and configuration or confidential production data.

9. Manufacturing Execution System – MES und Digital Twin

The Manufacturing Execution System (MES) from iTAC Software AG forms the central data hub. The MES receives order data from the ERP system and assigns a serial number to the semi-finished product, which is to be married to the finished end product. The MES assigns work steps, receives feedback from the equipment about the completed steps and enters the successful work steps in the system (Track & Trace). Information from the integration bus is sent to the MES, where the decision is made as to where to transport the product for further processing based on production plant topology and corresponding instructions are given to the flexible transport system. Key Performance Indicators (KPIs) are assessed using the production data generated and stored in the MES and can be read in real-time on the dashboard controls located on the line. Additionally, conclusions drawn in this way from production data facilitate the optimization of production process and preventive maintenance decisions. Clearly, the MES contributes greatly to a self-optimizing production system.

Aspects such as operational excellence, real-time transparency, predictive maintenance services, and quality assurance are visualized in the uniform and flexible production control center provided by IBM. Data from the various production modules is enriched and structured for storage in the Data Historian. Results derived from analysis of this data are used to avoid bottlenecks, waste, rework, and down time. Ultimately, the product, all modules, and even decisions out of the IT systems can be shown to the worker by a so called “Digital Twin” in real-time.